HP10098 BASIC INDEPENDENT AIR SPRING ACTIVATION KIT

HP10098 BASIC INDEPENDENT AIR SPRING ACTIVATION KIT

Thank you and congratulations on the purchase of a Pacbrake basic independent air spring activation kit. Please read the entire installation manual prior to starting the installation to ensure you can complete the installation once started. Plan the location and mounting of the control panel, compressor, airline routing and electrical connections before starting. BEFORE STARTING: Ensure the kit includes all the items shown in the photo. HP10098 IMPORTANT: This kit includes push-to-connect airline fittings. They require the end of the airline to be cut cleanly and square to ensure the internal seal will not leak air. The airline must only be cut with a sharp knife or hose cutter. Using scissors or wire cutters will distort the airline causing the connection to leak air past the o-ring seal. COMPONENT MOUNTING 1 Choose a location to mount the gauge and switch panel. It should be in reach and in clear view to the driver. Using the bracket as a template, mark and drill two 3 /16 diameter holes to secure the bracket. Do not install the bracket until the electrical and airlines are connected. 2 Thread sealant or Teflon tape must be applied to all the fitting threads installed throughout the installation to prevent air leaks. Installation of the compressor Install the push to connect fitting into the check valve, then install the assembly into the compressor head, As shown in photo. 1 2 3 The compressor makes an audible pumping noise when activated, Consider this when choosing a mounting location. The location should also be in a clean, dry area to maintain long compressor life. Using the compressor as a template, mark and drill three 3 /16 diameter holes. Secure the compressor using the fasteners provided. PG 2

COMPRESSOR AIR INTAKE FILTER 4 4 Locate the air intake filter housing, barbed fitting and 6' length of blue nylon hose provided in kit. Choose a location to mount the filter housing within 6' of the compressor, the housing requires a 1/2 hole for mounting, the location must also provide clean dry air. Secure the barbed fitting to the filter housing, connect the nylon hose to the barbed fitting, install the housing into the mounting hole. Route the nylon hose to the inlet fitting at the compressor, secure the hose with tie-straps provided. 5 ELECTRICAL CONNECTIONS 5 Provided in the kit is a pre-wired relay receptacle to make this part of the installation easy. Find a convenient location close to the positive battery terminal to mount the relay receptacle. Using the self tapping screw provided, secure the relay receptacle and install the relay provided. 6 Locate either one of the two red 12 gauge wires of the relay harness. Cut to length and connect the 30 amp fused link. Connect the 30 amp fused link to the positive terminal of the battery. Locate the second red 12 gauge wire and route to the compressor. Cut to length and crimp on the supplied blue butt connector, then connect to the red compressor wire. Locate the black wire of the compressor and connect to a good chassis ground or the negative battery terminal. Heat the connector s to provide a water tight seal. 6 7 Locate the 16 gauge red with white strip and the white wire of the relay harness. Route these two wires into the cab through the firewall boot. Connect the red with white strip wire to the 5 amp inline fuse provided, then to a 12 volt ignition power source using the T tap connector provided. Test the ignition power source with a volt meter prior to attaching the T tap. Some ignition circuits are less than 12 volts which may not be enough to activate the relay coil. This wire can be connected through an ON/ OFF switch to override the compressor activation, should the customer prefer this option. (Switch not provided in the kit, available separately) 7 Heat the butt connector s to provide a water tight seal. PG 3

ELECTRICAL CONNECTIONS AT THE REAR OF THE GAUGE 8 The red wire needs to be connected to the dash board illumination circuit using the T tap provided. NOTE: If the customer does not want the gauge light to dim with the dash lights, the red wire can be connected through an inline fuse to a 12 VDC circuit. The eyelet terminal with the single black wire and two white wires needs to be attached to a good chassis ground. 9 In the cab, locate the white wire routed into the cab in step 7 (originating at the relay harness). This wire connects to the white wires at the control panel with a blue heat shrinkable butt connector. Crimp the wire to the connector, then heat the connector to provide a water tight seal. 9 10 GAUGE PLUMBING 10 Locate the two 1 /8 NPT female push-to-connect fittings provided. These fittings are installed on the back of the dual needle gauge. Use thread sealant or Teflon tape. When tightening these fittings, hold the jam nut on the back of the gauge fitting to provide support. Using the black nylon airline provided cut off two 4 lengths. Insert one end of each length on to the barbed T fitting provided (fig 10). Connect the ends of the black nylon hoses to the port on the back of the switch marked supply (fig 10-3). 4 4 3 3½ 10-1 10-1 Using the green nylon airline provided, cut one length at 3 and the other to 3½". Connect the two airlines to the barbed T fitting provided, as shown in the photo (fig 10-1). Connect the 3½" long airline onto the R/H switch DELIVERY port. Insert the 3 long airline into the left air gauge supply fitting. 5 1½ 10-2 10-2 Using the red nylon airline provided, cut one length at 5 and the other to 1½". Connect the two airlines to the barbed T fitting provided, as shown in the photo (fig 10-2). Connect the 5 long airline onto the L/H switch DELIVERY port. Insert the 1½" long airline into the left air gauge supply fitting. 10-3 PG 4

PLUMBING CONNECTIONS 11 Using a sharp razor knife, cut the end of the black nylon tube off squarely, push this end firmly into the pushto-connect fitting on the compressor until it stops. Route the other end of the nylon hose through the firewall boot into the cab then to the gauge and switch panel (as shown in the drawing below). 12 The remaining lengths of red and green nylon airline are to connect the control panel to the air springs. The airline colour identifies which air spring they will be connected to. Red is for the left and Green is for the right air spring. Starting at the control panel, route two lengths of nylon airline through the firewall boot and along the frame rail to the correct air spring. Cut the ends of the airlines off squarely with a sharp knife, then push firmly all the way into the fitting at the air spring. Secure the nylon airline with tie-straps provided. 13 At the rear of the control panel, locate the three T fittings with different coloured airline. These colours pertain to where they get connected. Black is the supply line from the compressor to the control panel. Green is the inflate/deflate line to the right side air spring and red is the inflate/deflate line to the left side air spring. See diagram for airline routing. TO R/H SPRING TO L/H SPRING SWITCH VIEW FROM REAR GREEN GREEN GREEN DELIVERY SUPPLY BLACK GAUGE GREEN BLACK BLACK BLACK SWITCH BLACK BLACK DELIV SUPP 14 Using the fasteners provided, secure the control panel to the chosen mounting location. Secure the wiring and airlines with the tie-straps provided. TO COMPRESSOR Red / White Tracer OPTIONAL Compressor ON/OFF Switch 86 5 AMP Fuse 87 or 30 Ignition Power Source To Either 87 or 30 Red 14 Gauge Connector 30 AMP Fuse Battery 85 White 30 or 87 RELAY Green Airline R/H Air Spring Connector To Either 30 or 87 White Red 14 Gauge Black Airline Connector Air Filter Red Air Compressor Red Airline L/H Air Spring Air Supply Red To Dashboard Illuminated Circuit Chassis Ground PG 5

TESTING THE SYSTEM Turn the ignition ON, move the left paddle switch to the UP position. The compressor should activate and the left side needle of the gauge should show air pressure being delivered to the air spring raising the left side of the vehicle. Then move the left paddle switch to the lower position. The needle of the gauge should show the air pressure dropping and lowering the left side of the vehicle. Repeat on the right side switch. The right side air spring should raise and lower with movement of the switch. Check the system for air leaks, fill both air springs to a predetermined value, then periodically check the gauge for any air pressure loss. Repeat as necessary. DO NOT EXCEED 100 PSI TO THE AIR SPRINGS AT ANY TIME AIR LEAK CHECK Inflate both the air springs to 90 PSI. Use a dish soap and water mixture on all airline connections to detect air leaks. Repair as necessary and retest. Inflate the air springs to a predetermined value and then the following day recheck the pressure. If one or both of the air springs have lost pressure, a leak is present. The leak must be repaired and then retest the vehicle until no leaks exist. OPERATING YOUR VEHICLE WITH PACBRAKE AIR SUSPENSION Air springs have minimum and maximum pressure requirements. Never operate your vehicle with less than 10 PSI in the air spring and never inflate the air springs over 100 PSI. Damage to the air springs will result. Check the air pressure in the air springs daily for the first couple of days to ensure a leak does not develop. The air springs are designed to maintain the vehicles stock ride height with a load. Do not use the air springs as a means to lift the vehicle with no load. A rough ride will result. SERVICING YOUR VEHICLE WITH PACBRAKE AIR SUSPENSION When lifting the vehicle with a floor jack or hoist on the frame, never allow the air spring to limit the travel of the axle. Try to always jack the vehicle on the axle. Suspending the axle with the air spring limiting the axle travel will damage the air spring and void the air spring warranty. Patents pending. Pacbrake is a registered trademark of Pacbrake Company. Other trademarks used herein are property of their respective holders. PG 6 Printed in Canada _rev5.26.04.13